Painting & Coating Industry (PCI) logo Powder coating summit logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • MATERIALS
  • TECHNOLOGIES
  • RESOURCES
  • EVENTS
  • DIRECTORIES
  • EMAGAZINE
  • CONTACT
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest News
  • Market Trends & Reports
  • Price Alerts
  • Subscribe to eNewsletters
  • Global Top 10/ PCI 25
  • Weekly Featured Article
  • COATLE Word Game
  • PRODUCTS
  • Product News
  • Must See Products and Services
  • MATERIALS
  • Additives
  • Resins/Polymers
  • Pigments
  • Equipment
  • Distributors
  • TECHNOLOGIES
  • Adhesives
  • Architectural Coatings
  • FINISHING
  • Industrial Coatings
  • Nanotechnology
  • Powder Coatings
  • Solventborne
  • Special Purpose Coatings
  • Sustainability
  • UV Coatings
  • Waterborne
  • FINISHING
  • Finishing News
  • Finishing Technologies
  • Finishing Equipment
  • Finishing Today
  • RESOURCES
  • Columns
  • Blogs
  • Coatings Supplier Handbook
  • Podcasts and Videos
  • PCI Store
  • Classifieds
  • eBooks
  • Sponsor Insights
  • White Papers
  • COATLE Word Game
  • Columns
  • Ask Joe Powder
  • Did you know?
  • Distribution Dive
  • Focus on Canada
  • Formulating With Mike
  • Innovation Insights
  • Moody's Coatings Conundrums
  • Powder Coating Perspectives
  • Target the Market
  • TiO2 Insider
  • Blogs
  • Editor's Viewpoint
  • Industry Insights
  • Podcasts and Videos
  • COAT-IT! Podcast
  • Videos/PCI TV
  • EVENTS
  • Coatings Trends & Technologies Summit
  • Paint and Coatings Academy
  • Webinars
  • Calendar of Events
  • Lifetime Achievement Award
  • DIRECTORIES
  • Buyer's Guide
  • Equipment Directory
  • Materials Directory
  • EMAGAZINE
  • Current Issue
  • eMagazine Archive
  • China Issue Archive
  • Editorial Advisory Board
  • CONTACT
  • Contact Us
  • Advertise
  • Subscribe to eMagazine
  • Subscribe to eNewsletters
Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
      • Finishing Today
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
  • RESOURCES
    • Columns
      • Ask Joe Powder
      • Did you know?
      • Distribution Dive
      • Focus on Canada
      • Formulating With Mike
      • Innovation Insights
      • Moody's Coatings Conundrums
      • Powder Coating Perspectives
      • Target the Market
      • TiO2 Insider
    • Blogs
      • Editor's Viewpoint
      • Industry Insights
    • Coatings Supplier Handbook
    • Podcasts and Videos
      • COAT-IT! Podcast
      • Videos/PCI TV
    • PCI Store
    • Classifieds
    • eBooks
    • Sponsor Insights
    • White Papers
    • COATLE Word Game
  • EVENTS
    • Coatings Trends & Technologies Summit
    • Paint and Coatings Academy
    • Webinars
    • Calendar of Events
    • Lifetime Achievement Award
  • DIRECTORIES
    • Buyer's Guide
    • Equipment Directory
    • Materials Directory
  • EMAGAZINE
    • Current Issue
    • eMagazine Archive
    • China Issue Archive
    • Editorial Advisory Board
  • CONTACT
    • Contact Us
    • Advertise
    • Subscribe to eMagazine
    • Subscribe to eNewsletters
  • SIGN UP!
Paint and Coating EquipmentSustainableManufacturing Equipment

Achieving Sustainable Paint Operations with Electric Pumps

By Bill Heuer
graco
graco machine
pump comparison
graco
graco machine
pump comparison
January 1, 2014

Responding to the rise in energy costs and environmental concerns, U.S. manufacturers are being prompted to look at alternate technologies and processes to achieve sustainable finishing operations. This has particularly been true on the paint line. Since the dawn of centralized mix rooms, new strategies have been developed to improve efficiency, reduce operating costs and minimize environmental impact – all while delivering a world-class paint finish.

These changes include advances in mix room equipment, especially pumps. Although pumps have been a staple in mix rooms for decades, the technology has changed considerably. Up until the late 1960s, most automotive manufacturers were using 2-ball pneumatic pumps until paint plants became standardized and they started using centrifugal pumps.

Over the next 10-20 years pump technology continued to evolve, and many operations shifted to pneumatic 4-ball pumps because they reduce degradation and extend the paint life. This made them a great replacement for centrifugal pumps and ideal for industrial applications. For more than 30 years, pneumatic systems have been the accepted choice of most mix rooms because they are intrinsically safe, easy to operate, less expensive to purchase and use an existing power source in the plant.

Another option that never gained much traction in the United States is hydraulic pumps. Although they are more cost efficient than pneumatic systems (approximately 25%), they have a reputation for being messy. Hydraulic pumps are generally expensive to retrofit into existing operations, but can be a good option if installing into a completely new paint line.

Perhaps the most important emerging technology to reduce long-term energy consumption, especially in large plants building new mix rooms, has been the use of electric pumps.

With typically a higher up-front capital expense, electric 4-ball pumps often provide the largest energy savings in a typical finishing operation. Most notably, they offer direct conversion of electrical energy to mechanical pumping. This not only uses less energy, but it also eliminates the inefficiency of compressed air systems.

Air compressors have ongoing liabilities including leaks, maintenance and equipment downtime that can lead to further inefficiencies. In fact, the majority of air compressor costs are not from the initial capital investment, but rather from energy usage in its 10-year lifespan.

Another benefit of electrical pumping is the improved control and automation potential. Pumps often run during off shifts or non-peak operating modes. By automating the pump using off-production settings, the system can be set to operate only when absolutely needed – greatly reducing or eliminating energy consumption (Table 1).

One particular electric circulating pump, manufactured by Graco, demonstrates these benefits. The E-Flo DC has the ability to maintain constant fluid pressure like a pneumatic pump while delivering cost savings through the use of a highly efficient electric motor. This unique technology not only provides less pulsation at changeover for consistent finishes, it uses less energy – making it up to five times more efficient than similar-sized pneumatic pumps. It is also rated for use in hazardous locations.

One large North American manufacturer of heavy equipment quickly recognized the benefits of electrical pumping after making the switch. When a pneumatic pump needed replacing on their paint line, they decided to try something more efficient. After selecting and installing a Graco E-Flo DC electric pump because of its advanced control and networking features, painters could immediately tell that something was different about how the paint was being delivered to the gun. The rapid changeover of the pump led to less pulsation, delivering a smoother finish and ultimately making it easier to paint.

Another car manufacturer based in Europe was also looking for a more efficient pump. The small footprint of the E-Flo DC made replacing the existing pump pretty simple, and they were also impressed by how easy the system was to install. Because there was good surge performance on changeover, they noticed better, more consistent finishes. The simple controls also made it easier to train mix room employees.

To protect the pumps from premature wear, the E-Flo DC was also developed with an integrated runaway protection system that is standard on all models. If the pump exceeds a certain flow rate, it automatically shuts off. This safety mechanism not only prevents costly material loss, but also reduces maintenance and increases longevity of the product.

A leading truck manufacturer in North America saved a great deal of money and material because of this feature. When a long circulation line was damaged, the E-Flo DC went to work. Rather than pumping hundreds of gallons of paint out of the damaged circulation line, it was estimated that only five more gallons of paint pumped through the line before the integrated runaway protection stopped the pump. Because this line was connected to an E-Flo DC, this manufacturer saved thousands of dollars on material and cleanup costs, and could easily justify purchasing additional E-Flo DC pumps as a result of these savings.

Table 1 illustrates how switching from pneumatic to electrical pumps can yield thousands of dollars in savings for finishing operations.

Conclusion

 While it may be a challenge, achieving sustainable paint operations is possible. To be successful, remember that one size does not fit all. Do your homework. Evaluate current trends. And understand the unique requirements of your application. One thing is for sure, pump technology is continuing to evolve and electric pumps are really showing promise as an energy- and money-saving technology. They offer many great advantages that are prompting manufacturers to make the switch to electric.

KEYWORDS: Pumps Sustainability in Coatings

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Bill Heuer, Marketing Manager, Industrial Products Division, Graco Inc., Minneapolis, MN

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • pci1022-Kinaltek-Lead-1170.jpg

    A Novel Pigment Production Technology

    Following an extensive R&D program that demonstrated...
    Paint and Coating Pigments
    By: Jawad Haidar and Nitin Soni
  • pci global top 10

    2025 Global Top 10: Top Paint and Coatings Companies

    The following is PCI’s annual ranking of the top 10...
    Global Top 10 and PCI 25
    By: Courtney Bassett
  • 2025 pci 25

    2025 PCI 25: Top Paint and Coatings Companies

    PCI's annual ranking of the top 25 North American paint...
    Global Top 10 and PCI 25
    By: Courtney Bassett
You must login or register in order to post a comment.

Report Abusive Comment

Manage My Account
  • eMagazine
  • eNewsletter
  • Online Registration
  • Subscription Customer Service

The Coatings Minute: Print Returns with PCI’s New Showcase Issue

The Coatings Minute: Print Returns with PCI’s New Showcase Issue

The Coatings Minute: Your Inside Look at PCInnovations

The Coatings Minute: Your Inside Look at PCInnovations

CTT Registration Now Open

CTT Registration Now Open

The Coatings Minute: Your Guide to the 2025 Coatings Supplier Handbook

The Coatings Minute: Your Guide to the 2025 Coatings Supplier Handbook

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the PCI audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of PCI or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • Modern arapartment complex painted in bright colors.
    Sponsored byEPS - Engineered Polymer Solutions

    Architectural Polymers Leading the Way in Coatings Innovation

  • paint sprayer in a workshop
    Sponsored byallnex

    Enabling Performance and Compliance: allnex Introduces a New Line of VOC Exempt Solvent-Borne Resins

Popular Stories

No. 3 AkzoNobel

AkzoNobel’s $1.4B Divestment Signals Strategy Shift

PCI voices from the top

eBook | PCI Voices from the Top

Mergers and Acquisitions

RPM Expands Portfolio With Strategic Acquisition



PCI Buyers Guide

Submit a Request for Proposal (RFP) to suppliers of your choice with details on what you need with a click of a button

Start your RFP

Browse our Buyers Guide for manufacturers and distributors of all types of coatings products and much more!

Find Suppliers

Events

September 3, 2025

Coatings Trends & Technologies Summit

The Coatings Trends & Technologies (CTT) Summit is an annual conference for both liquid and powder coatings formulators and manufacturers to discuss innovations in coatings technology. This event combines high-quality technical presentations, a resource-rich exhibit hall, and dedicated networking opportunities to connect scientific minds, foster innovation, and cultivate game-changing new ideas!

January 1, 2030

Webinar Sponsorship Information

For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

View All Submit An Event

Poll

Longest-running laboratory experiment

What is the longest-running laboratory experiment?
View Results Poll Archive

Products

CTT Summit Short Courses (Live 9/3/25)

Coatings Trends & Technologies Summit is expanding its offerings with four short courses. These short courses will offer an extensive day of interactive learning.

See More Products
pci voices from the top ebook

PCI CASE EBOOK

Related Articles

  • EQUIPMENT: Electric Piston Pumps - Posted 5/23/07

    See More
  • BMW.jpg

    Electric Exhaust Purification System Powers Paint Shop Innovations

    See More
  • pci0320-Sabo-115813748-900.jpg

    Achieving Water Authority Compliance with Automated Wastewater Treatment

    See More
×

Keep the info flowing with our eNewsletters!

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletters
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey & Sample
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Youtube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
      • Finishing Today
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
  • RESOURCES
    • Columns
      • Ask Joe Powder
      • Did you know?
      • Distribution Dive
      • Focus on Canada
      • Formulating With Mike
      • Innovation Insights
      • Moody's Coatings Conundrums
      • Powder Coating Perspectives
      • Target the Market
      • TiO2 Insider
    • Blogs
      • Editor's Viewpoint
      • Industry Insights
    • Coatings Supplier Handbook
    • Podcasts and Videos
      • COAT-IT! Podcast
      • Videos/PCI TV
    • PCI Store
    • Classifieds
    • eBooks
    • Sponsor Insights
    • White Papers
    • COATLE Word Game
  • EVENTS
    • Coatings Trends & Technologies Summit
    • Paint and Coatings Academy
    • Webinars
    • Calendar of Events
    • Lifetime Achievement Award
  • DIRECTORIES
    • Buyer's Guide
    • Equipment Directory
    • Materials Directory
  • EMAGAZINE
    • Current Issue
    • eMagazine Archive
    • China Issue Archive
    • Editorial Advisory Board
  • CONTACT
    • Contact Us
    • Advertise
    • Subscribe to eMagazine
    • Subscribe to eNewsletters
  • SIGN UP!